Omron CJ1M-CPU21, CJ1M-CPU22, CJ1M-CPU23 Operation Manual

Cat. No. W372-E1-11

SYSMAC CS/CJ Series

WS02-LCTC1-EV5

CX-Process Tool Ver. 5.2

OPERATION MANUAL

WS02-LCTC1-EV5

CX-Process Tool Ver. 5.2

Operation Manual

Revised November 2007

iv

Notice:

OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual.

The following conventions are used to indicate and classify precautions in this manual. Always heed the information provided with them. Failure to heed precautions can result in injury to people or damage to property.

! DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Additionally, there may be severe property damage.

! WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Additionally, there may be severe property damage.

! Caution Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property damage.

OMRON Product References

All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to an OMRON product, regardless of whether or not it appears in the proper name of the product.

The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means “word” and is abbreviated “Wd” in documentation in this sense.

The abbreviation “PLC” means Programmable Controller. “PC” is used, however, in some Programming Device displays to mean Programmable Controller.

Visual Aids

The following headings appear in the left column of the manual to help you locate different types of information.

Note Indicates information of particular interest for efficient and convenient operation of the product.

1, 2, 3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.

Copyrights and Trademarks

Windows is a registered trademark of the Microsoft Corporation.

Other system and product names that appear in this manual are the trademarks or registered trademarks of the respective company.

OMRON, 2000

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of OMRON.

No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

v

About Loop Controllers

Loop Control Types, Functional Elements, and Versions

Loop Controller Types

There are two types of CS/CJ-series Loop Controller: Separate Loop Controllers and Loop Controllers Pre-installed in CPU Units

Loop	Type name	Product name	Model	PLC series and Unit type
Controller
type
Separate	Separate	Loop Control Unit	CS1W-LC001	CS-series CPU Bus Unit Loop
	Loop			Controller
	Controller
		Loop Control	CS1W-LCB01/05	CS-series Inner Board Loop Controller
		Board
		Loop Control	CS1W-LCB05-GTC	CS-series Inner Board Loop Controller
		Board with
		Gradient
		Temperature
		Controller
Pre-installed in	CPU Unit with	Process-control	CS1D-CPUjjP	A one-Unit Loop Controller consisting
CPU Unit	Pre-installed	CPU Unit		of an Inner Board pre-installed in a
	Loop			CS-series CS1D-H CPU Unit
	Controller
		Loop-control CPU	CJ1G-CPUjjP	An Inner Board Loop Controller
		Unit		integrated into a CS-series CJ1-H CPU
				Unit
		Loop-control CPU	CJ1G-CPUjjP-GTC	An Inner Board Loop Controller
		Unit with Gradient		integrated into a CJ-series CJ1-H CPU
		Temperature		Unit
		Controller

Loop Controller Functional Elements

•Separate Loop Controllers consist of only the Loop Controller functional element (i.e., the Loop Controller element).

•CPU Units with Pre-installed Loop Controller consists of a CPU Unit functional element (i.e., the CPU Unit element) and the Loop Controller functional element (i.e., the Loop Controller element).

Versions

The functional elements (i.e., the CPU Unit element and Loop Controller element) have versions.

Model Numbers and Functional Elements

The following table lists the Loop Controller product model numbers, the functional element names for the CPU Unit elements and Loop Controller elements, and the versions of the functional elements.

vi

	Product	Product model	Unit version		Configuration
	name	number	of the
				CPU unit element		Loop Controller element
			product
				CPU Unit	Functional	Functional	Functional
			model
				model with	element unit	element	element
			(See note.)
				same	version	name
				functionality
	Loop Control	CS1W-LC001	Pre-Ver. 2.0	---		LC001	Ver. 2.5
	Unit
	Loop Control	CS1W-LCB01	Ver. 2.0 or	---		LCB01	Ver. 2.0 or later
	Board		later
		CS1W-LCB05				LCB05	Ver. 2.0 or later
	Loop Control	CS1W-LCB05-	Ver. 3.0 or	---		LCB05-GTC	Ver. 3.0 or later
	Board with	GTC	later
	Gradient
	Temperature
	Controller
	Process-	CS1D-CPU65P	---	CS1D-CPU65H	Ver. 1.0 or later	LCB05D	Ver. 1.0
	control CPU
		CS1D-CPU67P		CS1D-CPU67H	Ver. 1.0 or later	LCB05D	Ver. 1.0
	Unit
	Loop-control	CJ1G-CPU42P	---	CJ1G-CPU42H	Ver. 3.0 or later	LCB01	Ver. 2.0 or later
	CPU Unit
		CJ1G-CPU43P		CJ1G-CPU43H	Ver. 3.0 or later	LCB03	Ver. 2.0 or later
		CJ1G-CPU44P		CJ1G-CPU44H	Ver. 3.0 or later	LCB03	Ver. 2.0 or later
		CJ1G-CPU45P		CJ1G-CPU45H	Ver. 3.0 or later	LCB03	Ver. 2.0 or later
	Loop-control	CJ1G-CPU45P-	Ver. 3.0 or	CJ1G-CPU45H	Ver. 3.0 or later	LCB05-GTC	Ver. 3.0 or later
	CPU Unit with	GTC	later
	Gradient
	Temperature
	Controller

Note Only Separate Loop Controllers have a unit version for the product model. CPU Units with Pre-installed Loop Controllers do not have a unit version for the product model.

Notation in this Manual

This manual uses the following notation.

•“Loop Controller” is used as a generic term to refer to the Loop Controllers in general.

•“LCBjj” is used to refer to specific Loop Controller functional elements. For example, the Loop Controller function element in a CS1W-LCB05 Loop Control Board is the LCB05, so “LCB05” is used to refer to the Loop Controller functional element. The Loop Controller function element in a CJ1G-CPU44P Loop-control CPU Unit is the LCB03, so “LCB03” is used to refer to the Loop Controller functional element.

•Model numbers are used to refer to specific Loop Controller models.

In the CX-Process Tool Operation Manual for version 3.2 or earlier, functional element names (LCBjj) are given as “Loop Control Board.” In the CX-Process Tool Operation Manual for version 4.0 or higher, simply “LCBjj” is used.

vii

Unit Version Notation on Products

Loop Control Boards

A “unit version” has been introduced to manage CPU Units, Special I/O Units, and Inner Boards in the CS/CJ Series according to differences in functionality accompanying upgrades. This system applies to Units manufactured since October 1, 2003. The unit version code is provided on the nameplate of the product for which unit versions are being managed, as shown below for the Loop Control Board.

Loop Control Board

Product nameplate

Unit version

Example for unit version 1.5

The CX-Process Tool can be used to confirm the unit versions of Loop Control Boards in the Monitor Run Status Window. After connecting the CX-Process Tool online, select Operation – Monitor Run Status from the Execute Menu. Confirm the unit version in ITEM099 (MPU/FROM version display) under from the System Common Block (Block Model 000) in the Monitor Run Status Window.

ITEM	Data name	Data
099	MPU/FROM version indication	V1.50

Version V1.50 and onwards must be indicated.

Functional Element Name and Version Code for Process-control CPU Units and Loop-control CPU Units

The functional element name and functional element version code for Processcontrol CPU Units and Loop-control CPU Units are provided on the nameplate as shown in the following diagrams.

viii

Process-control CPU Units

Note CPU Unit elements for which no version code is provided are pre-Ver. 2.0 CPU Units.

Functional element name for

Process-control CPU Unit	CPU Unit element
	Product nameplate

Nameplate on left side of Unit

	Functional element	Functional element
Functional element name for	version code for the	version code for
Loop Controller element	CPU Unit element	Loop Controller ele-
		ment

Functional element version code for

Loop Controller element

Loop-control CPU Units

Loop-control CPU Unit

	Product model and functional	Unit model number
		Product nameplate
	element name
		Functional element
		version code for
		CPU unit element
		Functional element
		version code for
	Recommended location for	Loop Controller
		element
	attaching version label
		Lot No.

Confirming CPU Unit Element Versions with Support Software

CX-Programmer version 4.0 can be used to confirm the unit version using either of the following two methods.

•Using the PLC Information

•Using the Unit Manufacturing Information (This method can also be used for Special I/O Units and CPU Bus Units.)

Note CX-Programmer version 3.3 or lower cannot be used to confirm unit versions.

PLC Information

1, 2, 3... 1. If you know the device type and CPU type, select them in the Change PLC dialog box, go online, and select PLC – Edit – Information from the menus. If you do not know the device type and CPU type, but are connected directly to the CPU Unit on a serial line, select PLC – Auto Online to go online, and then select PLC – Edit – Information from the menus.

2. In either case, the following PLC Information Dialog Box will be displayed.

ix

Functional element name for CPU Unit element

Functional element version code for CPU Unit element

Use the above display to confirm the unit version of the CPU Unit that is connected online.

Unit Manufacturing Information

1, 2, 3... 1. In the I/O Table Window, right-click and select Unit Manufacturing Information – CPU Unit.

2. The following Unit Manufacturing Information Dialog Box will be displayed.

x

Functional element version code for CPU Unit element

Use the above display to confirm the unit version of the CPU Unit connected online.

Functional Element Versions and Programming Devices

The Programming Device that supports the functional element version code must be used to enable all the functions in the corresponding functional element.

Note Upgrading versions is not necessary if only the basic functions of the CPU Unit element are required.

CPU Unit Element

Loop Controller		Programming Device
Functional	Functional	CX-Process Tool	CX-Programmer
element name	element version		(See note.)
CS1G/H-CPUjjH	Pre-Ver. 2.0	---	---
	Ver. 2.0		Ver. 4.0 or higher
	Ver. 3.0		Ver. 5.0 or higher
CS1D-CPUjjH	Ver. 1.1		Ver. 4.0 or higher
CJ1G-CPUjjH	Ver. 3.0		Ver. 5.0 or higher
	Ver. 4.0		Ver. 7.0 or higher

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Loop Controller Element

Loop Controller		Programming Device
Functional	Functional	CX-Process Tool	CX-Programmer
element name	element version		(See note.)
LCB01	Ver. 1.0	Ver. 3.0 or higher	---
	Ver. 1.5	Ver. 3.2 or higher
	Ver. 2.0	Ver. 4.0 or higher
	Ver. 3.0	Ver. 5.0 or higher
	Ver. 3.5	Ver. 5.2 or higher
LCB05	Ver. 1.0	Ver. 3.0 or higher
	Ver. 1.5	Ver. 3.2 or higher
	Ver. 2.0	Ver. 4.0 or higher
	Ver. 3.0	Ver. 5.0 or higher
	Ver. 3.5	Ver. 5.2 or higher
LCB05-GTC	Ver. 3.0	Ver. 5.1 or higher
LCB03	Ver. 2.0	Ver. 4.0 or higher
	Ver. 3.0	Ver. 5.0 or higher
	Ver. 3.5	Ver. 5.2 or higher
LCB03-GTC	Ver. 3.0	Ver. 5.1 or higher
LCB05D	Ver. 1.0	Ver. 3.1 or higher

xii

	TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		xxiii
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		xxiv
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		xxiv
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		xxiv
4 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		xxvi
SECTION 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1
1-1	CX-Process Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2
1-2	Relationship with CX-Process Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
1-3	CX-Process Tool Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
1-4	Version Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
1-5	Function Blocks/ITEMs Incompatible with Earlier Versions . . . . . . . . . . . . . . . . . . . . . .	25
1-6	Connecting to the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
1-7	Basic Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	36
1-8	Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44
SECTION 2
Preparations to Create Function Blocks . . . . . . . . . . . . .		49
2-1	Installing and Uninstalling the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	50
2-2	Overview of User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	69
SECTION 3
Creating Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . .		97
3-1	Creating Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
3-2	Using the CX-Process Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	132
3-3	Using the CX-Process Monitor Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	138
3-4	Using SCADA Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	141
3-5	User Link Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	159
3-6	Creating User-defined Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	173
3-7	Creating Step Ladder Program Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	180
3-8	Creating Sequence Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	195
3-9	Displaying and Setting in Engineering Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	207
3-10	Displaying Loop Controller Memory Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	212
3-11	Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	216
3-12	Setting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	224
SECTION 4
Online Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		235
4-1	Overview of Online Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	236
4-2	Initial Settings for Online Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	238
4-3	Downloading, Uploading and Comparing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	251
4-4	Run/Stop Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	264
4-5	Monitor Run Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	266
4-6	Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	270
4-7	Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	294
4-8	Backup and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	306
4-9	Transferring Tag and Comment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	309
4-10	Clear All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	313
4-11	Controlling the CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	314
4-12	Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	315
SECTION 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		317
5-1	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	318
5-2	Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	319

xiii

	TABLE OF CONTENTS
Appendices
A	Table of LC Type Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	323
B ITEM Notation in Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		325
C	Setting Segment Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	329
D	Sequence Table Design Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	337
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		339

xiv

About this Manual:

This manual describes the installation and operation of the WS02-LCTC1-EV5 CX-Process Tool software package and includes the sections described below. The CX-Process Tool is used to create and test function blocks for the CS1W-LC001 Loop Control Unit, the CS1W-LCB01, CS1W-LCB05, and CS1W-LCB05-GTC Loop Control Boards, the CS1D-CPUjjP Process-control CPU Units, and the CJ1G-CPUjjP and CJ1G-CPUjjP-GTC Loop-control CPU Units.

In this manual, the WS02-LCTC1-EV5 CX-Process Tool software package is generally referred to as simply the “CX-Process Tool.”

Please read this manual carefully and be sure you understand the information provided before attempting to install and operate the CX-Process Tool. Please read the following manuals carefully and be sure you understand the information provided before setting up or using an application for a Loop Control Unit/ Board.

xv

Product	Manual name	Cat. No.	Contents
WS02-LCTC1-EV5	CX-Process Tool	W372	Installation and operation
CX-Process Tool	Operation Manual	(this manual)	procedures for the CX-Process
			Tool.
CXONE-ALjjC-EV	CXONE-ALjjC-EV	W463	Provides an overview of the
2/ALjjD-EV2	2/ALjjD-EV2		CX-One and describes the
CX-One Ver. 2.0 FA	CX-One Ver. 2.0 FA		installation procedures for
Integrated Tool	Integrated Tool		CX-One software.
Package	Package Setup		Refer to this manual when
	Manual
			installing the CX-Integrator from
			the CX-One.
WS02-LCTC1-E	CX-Process Monitor	W373	Installation and operation
CX-Process Monitor	Operation Manual		procedures for the CX-Process
			Monitor.
WS02-LCMC1-E	CX-Process Monitor	W428	Installation and operation
CX-Process Monitor	Plus Operation		procedures for the CX-Process
Plus	Manual		Monitor Plus.
CS1W-LC001	Loop Control Unit	W374	Installation and operation
Loop Control Unit	Operation Manual		procedures for the Loop Control
			Unit (except for function blocks).
CS1W-LCB01/05	Loop Control Board	W406	Installation and operation
Loop Control Boards,	Operation Manual		procedures for the Loop Control
CS1D-CPUjjP			Boards (except for function
Process-control CPU			blocks).
Units, and
CJ1G-CPUjjP
Loop-control CPU
Units
CS1W-LC001	Loop Control Unit	W375	Detailed information on function
Loop Control Unit	Function Block		blocks for Loop Control Units.
	Reference Manual
CS1W-LCB01/05	Loop Control Board	W407	Detailed information on function
Loop Control Boards,	Function Block		blocks for Loop Control Boards
CS1D-CPUjjP	Reference Manual
Process-control CPU
Units, and
CJ1G-CPUjjP
Loop-control CPU
Units
CS1W-LCB05-GTC	Loop Control Board	W460	Provides information required
Loop Control Board	with Gradient		when using the gradient
with Gradient	Temperature		temperature control functions. For
Temperature	Controller		information not related to the
Controller	User’s Manual		gradient temperature control
CJ1G-CPU45P-GTC			functions, please refer to the
Loop-control CPU			Loop Control Board Operation
Unit with Gradient			Manual (Cat. No. W406).
Temperature
Controller

For details on procedures for installing the CX-Process Tool from the CX-One FA Integrated Tool Package, refer to the CX-One Ver. 2.0 Setup Manual provided with CX-One.

Cat. No.	Model	Manual name	Contents
W463	CXONE-ALjjC-EV	CX-One Ver.2.0	Installation and overview of
	2/ALjjD-EV2	Setup Manual	CX-One FA Integrated Tool
			Package.

xvi

Section 1 introduces the operations of the CX-Process Tool and connections to the PLC.

Section 2 describes installing the CX-Process Tool and provides an overview of the user interface.

Section 3 describes how to create and manipulate function blocks.

Section 4 describes online operations for uploading, downloading, and testing function block data.

Section 5 describes errors that can occur while using the CX-Process Tool.

! WARNING Failure to read and understand the information provided in this manual may result in personal injury or death, damage to the product, or product failure. Please read each section in its entirety and be sure you understand the information provided in the section and related sections before attempting any of the procedures or operations given.

xvii

xviii

Read and Understand this Manual

Please read and understand this manual before using the product. Please consult your OMRON representative if you have any questions or comments.

Warranty and Limitations of Liability

WARRANTY

OMRON’s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.

OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.

LIMITATIONS OF LIABILITY

OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.

In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.

IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.

xix

Application Considerations

SUITABILITY FOR USE

OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer’s application or use of the products.

At the customer’s request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use.

The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:

•Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this manual.

•Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry or government regulations.

•Systems, machines, and equipment that could present a risk to life or property.

Please know and observe all prohibitions of use applicable to the products.

NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

PROGRAMMABLE PRODUCTS

OMRON shall not be responsible for the user’s programming of a programmable product, or any consequence thereof.

xx

Disclaimers

CHANGE IN SPECIFICATIONS

Product specifications and accessories may be changed at any time based on improvements and other reasons.

It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the products may be changed without any notice. When in doubt, special model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products.

DIMENSIONS AND WEIGHTS

Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.

PERFORMANCE DATA

Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of OMRON’s test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and Limitations of Liability.

ERRORS AND OMISSIONS

The information in this manual has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.

xxi

xxii

PRECAUTIONS

This section provides general precautions for using the CX-Process Tool, CS/CJ-series Programmable Controllers (PLCs), and related devices.

The information contained in this section is important for the safe and reliable application of Programmable Controllers. You must read this section and understand the information contained before attempting to set up or operate a PLC system.

1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		xxiv
2	General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	xxiv
3	Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	xxiv
4	Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	xxvi

xxiii

Safety Precautions

3

1 Intended Audience

This manual is intended for the following personnel, who must also have knowledge of electrical systems (an electrical engineer or the equivalent) and instrumentation systems (a process engineer or the equivalent).

•Personnel in charge of installing FA systems.

•Personnel in charge of designing FA systems.

•Personnel in charge of managing FA systems and facilities.

2 General Precautions

The user must operate the product according to the performance specifications described in the operation manuals.

Before using the product under conditions which are not described in the manual or applying the product to nuclear control systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safety equipment, petrochemical plants, and other systems, machines, and equipment that may have a serious influence on lives and property if used improperly, consult your OMRON representative.

Make sure that the ratings and performance characteristics of the product are sufficient for the systems, machines, and equipment, and be sure to provide the systems, machines, and equipment with double safety mechanisms.

This manual provides information for programming and operating the Loop Controller. Be sure to read this manual before attempting to use the Loop Controller and keep this manual close at hand for reference during operation.

! WARNING It is extremely important that a PLC and all PLC Units/Boards be used for the specified purpose and under the specified conditions, especially in applications that can directly or indirectly affect human life. You must consult with your OMRON representative before applying a PLC System to the above-mentioned applications.

3Safety Precautions

!WARNING Check the following items before starting to run the LCBjj:

•Do not allow the bank of the EM Area with the number specified for allocation to the HMI (human-machine interface) data to be used by the CPU Unit or other Units for any other purpose. The block allocated for the HMI is specified in ITEM 050 (EM Area Bank Allocated for HMI Memory = 0 to 12) of the System Common block. If areas overlap, the system may operate in an unexpected fashion, which may result in injury.

•Do not allow the area to which user link table data is written to be used by the CPU Unit or other Units for any other purpose. If areas overlap, the system may operate in an unexpected fashion, which may result in injury.

•Analog Input/Output Units used in combination with the LCBjj must be mounted correctly, and the unit number set on the front panel of the Analog Input/Output Unit must match the unit number set on the Field Terminal block. If the unit numbers do not match, input/output (read/write) is performed on the data of another Special I/O Unit (i.e., the one whose unit number is set on the Field Terminal block).

•The defaults of the System Common block on the LCBjj must be set correctly.

xxiv

Safety Precautions

3

! WARNING Check the following items before starting Loop Controller operation:

Do not allow the area to which user link table data is written to overlap with any other area used by the CPU Unit or other Units. If areas overlap, the system may operate in an unexpected manner, which may result in injury.

When using a user link table to write bit data to I/O memory in the CPU Unit. Never allow ladder programming or communications processes in the CPU Unit to write to any bits in the words in which bits are written from a user link table. Depending on the timing, any attempts to write to these words from ladder programming or communications processes may be ignored. Example: If tag A in a user link table writes to bit 00 of W000 and an OUT instruction in the ladder program in the CPU Unit write to bit 01 of W000, the write from the ladder program may be ignored.

Analog I/O Units used in combination with the Loop Controller must be mounted correctly.

The unit number set on the front panel of the Analog I/O Unit must be the same as the unit number set on the Field Terminal Function Block. If the unit numbers are not the same, I/O (read/write) will be performed on the data for another Special I/O Unit (i.e., the one whose unit number is set in the Field Terminal Function Block).

The initial settings of the System Common Block in the Loop Controller must be set correctly. In particular, make sure that words in the Data Memory used for the Node Terminals in the CPU Unit controlling the Loop Controller are not used for other applications on the PLC.

When writing data to the I/O memory in the CPU Unit with function blocks (e.g., using Send All Blocks, Expanded DO/AO Terminal to CPU Unit, or DO/AO Terminal to CPU Unit), be sure that the words written to in I/O memory are not being used for any other purpose. If I/O memory words are allocated to more than one purpose, the PLC system may act unexpectedly and cause injury.

! WARNING Always stop the operation of the LCBjj before converting any of the EM Area to file memory. If any part of the EM Area that is being used by the LCBjj for the HMI is converted to file memory during Board operation, the system may operate in an unexpected fashion, which may result in injury.

! WARNING Do not perform processing in such a way that the Loop Controller and CPU Unit write to identical I/O memory words allocated to a contact output or analog output of an external Unit. If the same words are written to, the externally connected loads may act unexpectedly and cause injury.

! WARNING When the calibration function is executed, the MV (manipulated variable) will change due to changes in the PVs (present values) input to the control block. Therefore, set pseudo-input values to confirm safety when the MW changes before executing the calibration function. Devices may perform unexpected operations, resulting in serious accidents.

! Caution Before transferring function block data (initial setting data or operation data) to the Loop Controller, confirm that the destination for the data is correct and also confirm the overall safety of the system (including the Loop Controller). Not doing so may result in unexpected operation.

! Caution Before performing Validate Action, be sure to perform Compare on currently opened function files and the Loop Controller’s function block data. If there are inconsistencies in the registered function blocks (block address vs. block model), it will not be possible to perform Validate Action correctly.

xxv

Application Precautions

4

Before forcing changes of analog signals or contact signals using Validate Action, confirm the safety of the instrumentation system as a whole. Not doing so may result in unexpected operation.

! Caution When downloading a sequence table for the LCBjj (unit ver. 1.5 or later) that has been edited online with the CX-Process Tool version 3.2 or higher, confirm that the system will operate normally with the edited sequence. If the sequence is not suitable for operation, unexpected operation may result.

! Caution Confirm in advance the conditions at any node for which the sequence table is being edited over a Controller Link or Ethernet network. Not doing so may result in unexpected operation.

! Caution Confirm the status of connected devices before transferring the setting for the MV tight shut function and MV analog output reverse function to the Loop Controller. Devices and equipment may perform unexpected operations if the data destination is mistaken.

! Caution When the calibration function is executed, the MV (manipulated variable) will change due to changes in the PVs (present values) input to the control block. Therefore, set pseudo-input values to confirm safety when the MW changes before executing the calibration function. Devices may perform unexpected operations, resulting in serious accidents.

4 Application Precautions

Observe the following precautions when using CX-Process Tool and Loop Controller.

! Caution If the power supply is turned OFF while function block data is being backed up from RAM to flash memory, the backup will not be completed normally. If the power supply is turned back ON within 24 hours, however, the super capacitor will have held the RAM data. The backup operation will restart when power is turned ON and operation will start when the backup has been completed. If the power supply is turned OFF for more than 24 hours, however, RAM data will be lost and operation will be started with the data that was previously saved to flash memory. If this happens, the Cold Start Auto-execution Flag (A35807) will turn ON to show that the previous data has been used. Use this bit in programming to take whatever steps are necessary, such as downloading the most recent function block data. (For LCBjj only)

! Caution Loop Control Unit data is monitored and operated using CX-Process Monitor or CX-Process Monitor Plus based on the monitor tag files created using CX-Pro- cess Tool. When creating monitor tag files using CX-Process Tool, CX-Process Monitor must be installed on the same computer.

! Caution Before using function block data in actual operation, confirm operation by monitoring run status (to check the load rate; select Execute/Operation/Monitor Run Status) and validating actions (select Validate Action/Start) with CX-Pro- cess Tool. In particular, be sure to confirm that the load rate will be less than 60%. (For details on the load rate, refer to the Operation Manual for the Loop Controller.)

xxvi

Application Precautions

4

! Caution When uploading the Loop Controller’s function block data, observe the following precautions.

When performing Upload New for Loop Control Units of version 1.5 or earlier, data on the Edit Block Diagram Screen (function block information) will be lost, and the block diagram showing the connections between function blocks will not be displayed.

When performing Upload Previous, if the data in the source file currently opened using the CX-Process Tool and the Loop Controller’s function block data does not match the registered function blocks or the data on the Edit Block Diagram Screen, the data currently opened may change to illegal data.

! Caution The Loop Controller can read and write I/O memory in the CPU Unit using the Field Terminal Function Blocks or CPU Terminal Blocks independent of the user program (Step Ladder Program) in the CPU Unit. Do not write to the same I/O memory words from both the Loop Controller and the CPU Unit.

! Caution To hold an analog output or contact output at a specific value (for example, the maximum value or minimum value) when the Loop Controller stops running, create a Step Ladder Program in the CPU Unit so that the corresponding output bit allocated to Analog Output Unit or Contact Output Unit is set to the desired value using an NC condition of the Loop Controller Running Flag (bit 00 in allocated CIO word “n”) as an input condition.

! Caution If a fatal error occurs in the CPU Unit (including fatal errors created by execution of a FALS instruction), the Loop Controller will also stop running. To hold analog outputs to the previous values before the stop occurred, and to set analog outputs to either the minimum value or maximum value, use the output hold function of the Analog Output Unit or Analog I/O Unit.

! Caution Before turning ON the power to the PLC, make sure that the facilities are safe. The analog output values and contact outputs from the Loop Controller are updated when the power to the PLC is turned ON regardless of the operating mode of the CPU Unit (including in the PROGRAM mode). (Internally, the analog output values and contact outputs are sent from the CPU Unit to Basic I/O Units and Analog Output Units.)

! Caution Fail-safe measures must be taken by the customer to ensure safety in the event of incorrect, missing, or abnormal signals caused by broken signal lines, momentary power interruptions, or other causes.

! Caution Confirm that no adverse effect will occur in the system before attempting any of the following:

•Changing the operating mode of the PLC (including the setting of the startup operating mode).

•Force-setting/force-resetting any bit in memory

•Changing the present value or any set value in memory

!Caution Be sure that all mounting screws, terminal screws, and cable connector screws

are tightened to the torque specified in the user manuals. Incorrect tightening torque may result in malfunction.

xxvii

Application Precautions

4

! Caution In the event of system or power failure, CX-Process function files (extension “.ist”) may not be saved. It is recommended that function files are saved regularly.

! Caution Do not connect pin 6 (+5 V power supply line) of the RS-232C port on the CPU Unit to any external device except the CJ1W-CIF11 RS-422A Adapter or NTAL001 RS-232C/RS-422A Adapter. Doing so may damage the external device or CPU Unit.

xxviii

SECTION 1

Introduction

This section introduces the operations of the CX-Process Tool and connections to the PLC.

1-1	CX-Process Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2
	1-1-1	Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2
	1-1-2	Project Workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
	1-1-3	Files Created with CX-Process Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
	1-1-4	Relationships between Tag Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	1-1-5	Operating Conditions of CX-Process Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
1-2 Relationship with CX-Process Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			9
	1-2-1	Overview of the CX-Process Monitor and CX-Process Monitor Plus . . . . . . . . .	9
	1-2-2	Settings Required on the CX-Process Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
1-3	CX-Process Tool Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		13
1-4	Version Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		15
	1-4-1	Version 1.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
	1-4-2	Version 1.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
	1-4-3	Version 2.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
	1-4-4	Version 2.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	1-4-5	Version 3.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	19
	1-4-6	Version 3.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
	1-4-7	Version 3.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
	1-4-8	Version 4.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	1-4-9	Version 4.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	1-4-10	Version 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
	1-4-11	Version 5.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
	1-4-12	Version 5.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
1-5 Function Blocks/ITEMs Incompatible with Earlier Versions . . . . . . . . . . . . . . . . . . . . . . .			25
	1-5-1	Incompatibility with Versions Earlier than Version 1.20 . . . . . . . . . . . . . . . . . . . .	25
	1-5-2	Incompatibility with Versions Earlier than Version 1.50 . . . . . . . . . . . . . . . . . . . .	25
	1-5-3	Incompatibility with Versions Earlier than Version 2.00 . . . . . . . . . . . . . . . . . . . .	26
	1-5-4	Incompatibility with Versions Earlier than Version 2.50 . . . . . . . . . . . . . . . . . . . .	28
	1-5-5	Incompatibility with Versions Earlier than Version 3.2 . . . . . . . . . . . . . . . . . . . . .	29
	1-5-6	Incompatibility with Versions Earlier than Version 4.0 . . . . . . . . . . . . . . . . . . . . .	30
	1-5-7	Incompatibility with Versions Earlier than Version 5.0 . . . . . . . . . . . . . . . . . . . . .	30
	1-5-8	Incompatibility with Versions Earlier than Version 5.2 . . . . . . . . . . . . . . . . . . . . .	30
1-6 Connecting to the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			31
	1-6-1	Features of FinsGateway and CX-Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
	1-6-2	Selecting the Communications Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
	1-6-3	Using FinsGateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
	1-6-4	Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
1-7	Basic Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		36
1-8	Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		44
	1-8-1	Creating Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44
	1-8-2	Online Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	46

1

CX-Process Tool

Section 1-1

1-1 CX-Process Tool

1-1-1 Overview

The CX-Process Tool supports the following functions for Loop Controllers.

In this manual, the WS02-LCTC1-EV5 CX-Process Tool software package is generally referred to as simply the “CX-Process Tool.”

•Creating function blocks, including the following functions

•Setting the Step Ladder Program Block (block 000), including the following: System common operation cycle, Loop Control Unit number (Loop Control Unit only), start mode, first address of data memory of node terminal (Loop Control Unit only)

•Registering function blocks (allocating block addresses)

•Connecting function blocks with analog and accumulator signals

•Setting ITEMs in function blocks

•Editing sequence tables (Block 302) and the Step Ladder Program Block (Block 302) (See note.)

Note Editing sequence tables is supported only by the CS1W-LCB05 Loop Control Board (00-LCB05) and CS1D-LCB05D Loop Control Board (00-LCB05D).

•Settings tags for CX-Process Monitor (Loop Control Unit only) or CX-Pro- cess Monitor Plus software or setting CSV tags for SCADA software (Tag Names and Analog Signals) and creating monitor tag files (Loop Control Unit only, CX-Process Monitor must be already installed), or CSV tag files.

•Downloading function block data to Loop Controllers

•Uploading data from Loop Controllers

•Comparing function block data with data in a Loop Controller or Function Block File

•Sending Run/Stop Commands to Loop Controller

•Monitoring status (including System Common Block Settings, Load Rate per Operation Cycle Group, and Execution Errors)

•Monitoring actions of Loop Controllers (including operation checks on function block diagrams and ladder diagrams)

•Tuning parameters such as PID constants in function blocks (Control Blocks)

•Backing up function block data from the Loop Controller’s RAM to flash memory and restoring that function block data from flash memory back to RAM

•Initializing function block data in Loop Controllers

Note To create monitor tag files using the CX-Process Tool with the CX-Process Monitor or CX-Process Monitor Plus software, both the CX-Process Tool, and CXProcess Monitor or CX-Process Monitor Plus, must be installed on the same computer.

2

CX-Process Tool

Section 1-1

1-1-2 Project Workspace

Project Workspace can be used to access the data created in memory with the CX-Process Tool. Data can be created for up to 32 CPU Units and 96 Loop Control Units (3 Loop Control Units each for 32 CPU Units) or 32 LCBjjs (1 LCBjj each for 32 CPU Units). The data has the following configuration.

		LCU/LCB Elements	Function Block Groups
			System common
		(one for each Loop
	Function Block File	Controller)	Field terminals
	for Each Node (.ist)	00-LCB03	Function Blocks
	Node01.ist	00-LCB01
	Node02.ist	00-LCB05	Basic PID
		00-LCB05D	Block diagrams
	Project Workspace	01-LC001

02-LC001

Node32.ist 03-LC001

Project file (.mul)

Project Workspace data is stored in one folder called the project folder. Project folders are created for the following commands.

•File – New

When a new project is created, the project name will be used as the folder name.

•File – Save As

When a project is saved under a new name, the new project name will be used as the folder name.

1-1-3 Files Created with CX-Process Tool

The CX-Process Tool creates a folder with the project name in the data folder under the default installation folder for the CX-Process Tool, and then creates the following files inside the project folder.

Project File (.mul)	The project file consists of administrative data for the Project Workspace.
	Files	File name	Remarks
		extension
	Function block files	.ist
	Block diagram information files	.mtbd
	Mnemonics/Ladder diagram	.mtld
	information files
	Comment files	.cmt
	CSV tag setting files	project_name.csv
	CX-Server configuration files	.cdm	Only when CX-Server is
			selected as the
			communications driver
	Job information files	.sjb
	Loop Controller configuration	.lcb
	files
	Data files of user link tables	LnkTable.csv
	Data files of sequence tables	.stbl

The project file (.mul) can be specified when opening files so that the above related files will be all read at the same time. The project file is created by selecting New from the File Menu and specifying the project name. The file name will be the same as the project name.

3